Battery Module Side Frame Turn-Around Width Design
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Solution Overview
Problem
Battery modules in electric vehicles face movement and dimensional variation issues due to cell expansion caused by temperature changes and aging deterioration, leading to deformation of side frames and potential failure in maintaining the structural integrity of the cell stack.
Innovation Solution
A battery module design featuring side frames with wider turn-around portions on the front and rear surfaces of the cell stack body, connected by bridging portions, which enhances the pressing force against the cell stack and increases rigidity, while optimizing thickness and weight reduction through strategic width configurations and integral bridging portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the side frames include narrow turn-around portions, then the device complexity is reduced, but the front and rear end plates may deform in an opening direction due to cell expansion loads
Solution Approach 1:
The patent changes the width parameter of the turn-around portions to be larger than the side frame body width, which increases the pressing force on the cell stack body and prevents end plate deformation while maintaining structural simplicity
Solution Approach 2:
The side frames are designed with pre-determined width dimensions for the turn-around portions that are larger than the side frame body, creating preliminary pressing force against the cell stack body to prevent future deformation from cell expansion
2Reliability
If the turn-around portions are made wider to increase pressing force, then the end plate stability is improved, but the size and weight of the battery module increase
Solution Approach 1:
The patent applies local quality by making only the turn-around portions wider than the side frame body, concentrating the additional material where pressing force is needed, while keeping other parts of the side frame narrow to minimize overall weight increase
3Strength
If the side frames are made more rigid to prevent deformation, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent achieves increased rigidity by changing the width parameter of the turn-around portions, which is a straightforward dimensional modification that can be implemented through standard manufacturing processes without complicating the fabrication method
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively prevents end plate movement and deformation, enhances structural rigidity, and reduces size and weight, while maintaining the structural integrity of the battery module under increased load conditions.
Implementation Method 1
the front turn-around portion and the rear turn-around portion each has a width (e.g., widths W3 and W4 in an embodiment) in a front-rear direction larger than a width (e.g., a width W5 in an embodiment) in a left-right direction of the side frame body
Data Source
AI summary
A battery module includes: a cell stack body; a pair of end plates disposed on a front surface and a rear surface of the cell stack body; and a fastening frame connecting the pair of end plates. The fastening frame includes; a pair of side frames disposed on the right surface and the left surface of the cell stack body. The pair of side frames each includes: a side frame body; a front turn-around portion that turn around the front surface of the cell stack body; and a rear turn-around portion that turn around the rear surface of the side frame body. The front turn-around portion and the rear turn-around portion each has a width in a front-rear direction larger than a width in a left-right direction of the side frame body.